Resinoid bonded cutting-off grinding wheels and method of cutting metals



United ws 2 floss assmem rosem- CUTTING-OFF cnnuinwc" WI-IEELS AND METHOD OF CUTTING METALS Stone, Worcester, assigfior to Nor ton Company, Worcester, Mass a corporation of Massachusetts I No fiiiiiiig appraisa Jiji l'y ll, i'lifi, sieri'al N 291,9 q 6 clinis'. (at. 51-20;)

The invemte'h' elates to iesiiioid b'onded' g'rindmfi wheels an with g r o i smqr fil ifiq e ur s; t cutti off wheels for cutting[ s uch ,as in the former rods; shafts, bars," sheet'sgand' thfe lik and the invention: also relates tofla Ineth 1 of cutting the v .Thisf applicafl qt i lafiqn-tnrp r ,dfij on n n ai -m cat on serial N6. 233,709 filed" June 26, r951 new aba'rid'ofltl. p U

ose object of theinventio'ii is as provide" a cutting-off wheel which will not stall Another o 'ec't of thelinvention is to, provide .a. tie tuning 'tll-diwlieel. Another object or theinyentionis'. to irfdvijde' a; wheel for grinding an; the perip ides? fia 'isl. Q LW i 1. l1 Y. L.a la I of friction against various metals. Anothe'; jeet'lbfthj invention is to provide cutting-off wheels' was side faces treated to reduce the po'wer'i equ'ired to drive the wheels.

Other objects will be in part obvious or in part pointed out hereinafter. I, I

Quitting-elf. wheelshave for years been made of abrasive bondedj with phenolic resin. Many patents have been $Q i 2 ps Pr cedure orth; manutacmreof ph.e.-. ic r es in,bonded wheels. different fillers, have been used in such wheels; Essentially the phenolic res bond is a polymer consisting of phenolic, g linked together with methylene CHLgroi1'p's' withv or w out additional across-linkages. It is well reactive phenolic r'ejs'in usually contains some hexamethyl enetetramineand for some oi the phenolic, QsHsOH, srs ss 'F. X 9lll? ;.i!l .;wh. ;h...t e oflthe hrdsds slams? ths be zen .s naissep asedt x .methyl,..eam. snbstitu d t l pally thngresylicgroups.are derived-from metacre sol However the cresylic groups are always in 'q rrrqr rt yarious fillers ean b used along withithe abrasive, t ry mple sulslil .imarxrit san magnum flu'otons.

and for this purposefurfural is often employed but liquid. reactive phenolic. resin is also used to a large extent. ,In' the illustrative example 1- wet the abrasive grain with liquid phenolic resin of the smasassaz, then add. athoroughniixtufe of iron pyrites (25%) and powdered reactive. phenolic resin of the brand BR24 17 G75% The abrasive g'rain which was used to makeup the .wheels that were subjected to the tests as hereinafter described was fused alumina of 2 4 r'it size. l h Iacalised the manufacture of a number of wheels twelve inches in diameter by three-thirty seconds of an inch thickhaving oneinch central holes out of phenolicre's'iin abrasiven'iiX. These wheels were made-in steel molds of conventional type consisting of a hollow cylindrical mold band, topland bottom plates of disc shape with central holes and a cylindrical mold arbor fittihg therein. Naturally the inside diameterof the mold bands was twelve inches, the diameter of thearbor's was one inch and the' holes in the mold plateswere one inch in diameter. The abrasive grains were first thoroughly wet with liquid resin leaving no substantial excess of liquid and then' themixture of powdered phenolic resin and iron pyr'ite's was added while -mixi'ng'. After pressih, the wheels were heat treatedin conventional manner by slowly heating to 175 C. and thil maintaining their at this temperature for about twenty-four hours. The wheels were pressed cold at a pressure of about 425 Some of these wheels had plain sides; that tasty nothingwas done to he-sides and as the mold plates were smooth the sides of the wheels were smooth. other b'o'gage allofywhich; have b'een reported in fiatentsi a wi h phen qlicresin and mreauhe sides of the wheels manner to be fully described As thelart is fully. fam ar with the manufacture of phenolicpresin'bonded lcdi g wheels, and the cprpposit-ion thereot.including fillers l. shall; give but a brief; ,egtan iple of suchlm'a'nu factureandnt will be understood that any desired phenolic resinbpnd and any desired filler can be used and that any, abrasive can be selected. In the manufacture ofpheii'olid ros in" L d which; it has been efiica'iol is" fi i s't to wet the athlete wheels had eightpo'und wand pulp paper, seetire aia; the sides-thereof and still other-wheels had" the sa e paper coatedwith tin secured to the sides thereof. Q f th'e tin coatedpaper some Had .908 grain of tin per s'duare .cen; tir'heter thereon and other paper had .0125 gra n of per square centimeter thereon The paper; liotljrthat coated with tin and the linc oatedjiafie'r, wasapplied to the wheel by placing a" sheet 61 to twelve inches in diameter with a she inch een'tral' h, the and 61'; top of the bottom plate with the tiri c ti was ati'n' coating on the tenant, and pl sheet on top of the miit" with the tin cast was a tin coating on top, then placing the top mold plate on top of the paper. All this, of course, was done before pressing and after pressing, the paper sheets, both those coated with tin and those not coated, were raise to be secured tame uncured wheels and after curing by heating, asflaforsaid, the paper was firmly bonded to the wheel surfaces.

For applying the tingto the paper a resinous assesses was made of 300 grams of powderedtin;- sonat powdered phenolic res'ifilBRQMl]I.aiirlljlll) cubic centimeters of,,is0,prop,yl alcohol.v .Thissuspension was then spread onto the paper which was then dried under heat lamps. By spreading more or less, the required amount of tin per square centimeter can be incorporated onto the paper.

These wheelmwereteslt dfiu ,5; Campbell No. 213 cutofl machine. This" machiYn eQhas a hydraulic down feed to force the wheel through the workpiece which is held rigidly by achuck. The hydraulic pressure moving the wheehdown canbe preset and in: each case was s't'fo' p s p squa n h, Pre s re. -Measurement, was made of the peak power used by the electric motor which grivesfli wheel. This measurement was. made by a q .s' w meter. s u h, a shss tstwere ma e in one second o'f time or less, it was not feasible tg eval 3 through therod except that when the wheel stalled no further cuts were made. Although the machine was set to give 90 pounds pressure it must be understood that the pressure necessarily varied as the wheel moved through the workpiece due to the characteristics of hydraulic feeding mechanism. In each series of tests represented by the following Tables I, II and III, one or more naked wheels were used for the purpose of comparison. These as well as the wheels having a coating of plain paper and the wheels having the coating of paper with tin were factory made wheels and as shown in Tables I and II were not exactly alike but were as near alike as can usually be obtained. The naked wheels of Table II are substantially the same as the naked wheel of Table III and the difference in peak power is readily explained by the condition of the machine, the temperature of the oil and other unavoidable varying factors from day to day but the tests of Table I were carried out at the same time under the same conditions, the tests of Table II were carried out at the same time and under the same conditions, and the tests of Table III were carried out at the same time and under the same conditions wherefor each table is valid for the comparison between items thereon but items of one table should not be compared with items of another table. In this connection peak power indications are very sensitive which explains the general discrepancy between Tables II and III but the fact that repeated tests consistently showed the metal coated paper covered wheels to cut more freely is a valid indication that they do cut more freely, other conditions being equal, and it should be borne in mind that these metal coated paper coated wheels were each used to make at least 40 cuts, Table I has no column for peak power because Table I represents the first experiments in which a general evaluation of the invention was made.

In the tables the wheels having no paper at all are identified by the words Naked Wheel in the column headed Wheel, the wheels having paper without any tin or other substance on the sides thereof are identified by the words Plain Paper in the same column, and the wheels having paper on the sides coated with tin are identified as Paper and .008 gm./cm Tin and Paper and .0125 gm./cm Tin respectively and the foregoing designations give the amount of tin in grams per square centimeter. In Table I under Burn, the designations are self-explanatory, but it may be remarked that a blue burn is worse than a brown burn.

Table I Whgel Wear on ame er Wheel in Inches per Burn Out . 0085 None. 11 60% Blue. .014 20% Brown.

Table II 60 Average Wheel Wear Peak Wheel on Diameter Power Remarks m Inch? in Kilo- 5 per cu watts Naked Wheel No measure- 32. S t a l l e d 7th men Gut. Do do 32. 8 Do. Plain Paper .010 31. Stalled 9th Cut. 70 Do .010 32.5 Sljlled 8th u Parpg and .008 gmJcmJ .0094 27. 4 Did not stall. P1 and .0125 gmJcm. .010 231) Free cutting.

Table III Wheel Average Wear on Peak Wheel Diameter Power Remarks in Inches in Kiloper Cut watts Naked Wheel .0088 19.9 Stalled on Cuts 36-40 inclusive. Plain Paper .0094 19. 0 Stalled on Cuts 13, and 17. Paper and .008 gun/em. Thu-.. .0045 13. 9 Free cutting.

I believe the action of the tin is to reduce the friction between the sides of the work piece and the wheel. This is a very important thing to do because all manufacturers are interested in reducing the time required for cutting-off operations as much-as possible and the way to do this is to speed up the wheels and increase the pressure, but of course each of these requires more power and in every case it is found that so much pressure can be used and no more, otherwise the motor will stall, but by lubricating the cut in accordance with this invention greater pressure and/or higher speed can be used without stalling any particular motor. Of course if more and more power is supplied to match increase of speed and pressure finally the wheel will break, but this eventuality too will be postponed by the use of tin coated side face wheels.

Tin is soft and has a low melting point. Other metals of characteristics similar to tin which can be used in this invention are antimony, bismuth, cadmium, gallium, indium, lead, thallium. The following table gives the melting points and the positions in the periodic table of these metals.

Table IV Melting Metal Symbol Group gg g Centigrade Antimony 5 51 630 Bismuth..-. 5 83 271 Cadmium... 2 48 321 Gallium-. 3 31 30 3 165 4 82 328 3 81 304 4 50 232 Various alloys of the foregoing metals are known and any alloy of two or more of the metals in the above list can be used, for example one eutectic fusible alloy having a melting point of 96 C. is 53 Bi, 32 Pb, 15 Sn. Another eutectic fusible alloy is 52 Bi, Pb, 8 Cd having a melting point of 91.5 C. Rose metal is Bi, 27 Pb, 23 Sn. Lipowitz alloy having a melting point of about C. is 50 Bi, 27 Pb, 13 Sn, 10 Cd. Woods metal having a melting point of 65.5" C. is 50 Bi, 25 Pb, 12.5 Sn, 12.5 Cd. Bizmuth solder having a melting point of 111 C. is 40 Bi, 40 Pb, 20 Sn. Another eutectic fusible alloy having a melting point of 103 C. is 54 Bi, 26 Sn, 20 Cd. Battery plate metal which melts at 300 C. is 94 Pb, 6 Sb. Antimonial lead which melts between 245' C. and 290 C. ranges from 92 to 94 Pb and 6 to 8 Sb. Magnolia metal which melts at about 270 C. is 90 Pb, 10 Sb or Pb, 15 Sb. Type metal is 82 Pb, 15 Sb, 3 Sn. Aluminum solder melting at 310 C. is 92 Pb, 8 Cd. Marine babbit is 72 Pb, 21 Sn, 7 Sb. Plumbers solder melting at 275 C. is 67 Pb, 33 Sn. Another type metal ranges from 56 to 60 Pb, 10 to 40 Sn and 4.5 to 30 Sb. Solder half and half melting at 225 C. is 50 Pb, 50 Sn. Brittania metal melting at 25 C. is Sn, 10 Sb. An alloy of tin and antimony is 80 Sn, 20 Sb melting at 320 C. An alloy of tin and cadmium is 68 Sn, 32 Cd melting at 180 C. Tinmans solder melting at 240 C. is 67 Sn, 33 Pb. Tinsel is 60 Sn, 40 Pb. A eutectic fusible alloy melting at C. is 50' Sn, 32 Pb, 18 Cd.

All of the above alloys can be used as all of them will melt during the grinding operation to lubricate the cut. Furthermore although the above examples do not give alloys of gallium, indium and thallium this is because those are rare or expensive metals but alloys thereof with each other and with other metals in the list can be made. In general some alloys of any two, three or four of the metals of table IV and probably of all of them can be made since the metal having the lowest boiling point is cadmium (778 C.) and this is higher than the melting point of the metal having the highest melting point to wit antimony. If an alloy of any two or more of the metals of table IV can be made, it can be used in this invention as any such alloy which can be made will have a melting point low enough for the purposes of this invention and most of them will have a melting point below that of antimony. However tin is preferred to the other metals or alloys having large proportions of the other metals because to some degree at least the others are poisonous although to such a slight extent that they nevertheless can be used.

A coating of metal can be applied to the sides of the wheel in any desired manner, the manner described being merely illustrative. For examplea Schoop type of spray gun to spray metal can be used, and such metalspray guns are readily available on the market. For disclosure of such a spray gun see U. S. Patent to E. Morf No. 1,100,602.

I believe this coating will be effective to some extent if it has a density of at least .004 gram per square centimeter. Such a coating, if uniform, which it does'not have to he, would be .00055 centimeter thick or approximately .00022 inch thick. This calculation is based on tetragonal tin having a specific gravity of 7.3 and the tin which I used was tetragonal tin.

Much thicker coatings can be used, however, provided the metal is granular. However too thick a coating would be detrimental because of the non-abrasive action of the metal and I believe that good results can be obtained with coatings up to .010 inch thick but not thicker.

Naturally most cutting-oif wheels are not used in the cut right down to the central hole so in most cases it will be suflicient if the outer half of the area of the sides 'of the wheel is coated to the extent indicated. I mean that an area bounded by concentric circle the outer one of which is the periphery of the wheel, said area being equal to one-half the total area of the wheel including the central hole should be coated and that is enough. The radial length of such an area,'where the radius of the wheel is r, is .3r. Thus in many cases it will be sufiicient if the .wheel sides are coated with metal from the periphery to three-tenths of the distance to the center although in other cases it will be desirable to coat the sides half way or more than half way from the periphery to the center.

The sides of cutting-01f wheels are flat, that is they are either planes or approximate planes. They may be dished inwardly towards the center of the wheel by a few thousandths of an inch.

Further with regard to how much coating is required to achieve the purposes of this invention to a significant degree, there can be bare spots (uncoated places) on the wheel sides because the lubrication persists long enough to make bare spots immaterial provided the average density of the coating at any distance more than .7r from the center, where r is the radius of the wheel, is .004 gram per square centimeter. This is the same as 0.000056892 pound per square inch.

It will thus be seen that there has been provided by this invention grinding wheels in which the various objects hereinabove set forth together with many thoroughly practical advantages are successfully achieved. As many possible embodiments may be made of the above invention and as many changes might be made in the embodiment above set forth, it is to be understood that all matter hereinbefore set forth is to be interpreted as illustrative and not in a limiting sense.

I claim:

1. A cutting-off grinding wheel comprising abrasive granules bonded together withv phenolic resin bond and having a grinding periphery and flat parallel sides and a coating of metal on each side thereof said metal being selected from the group consisting of antimony, bismuth, cadmium, gallium, indium, lead, thallium and tin and alloys thereof, said coating of metal on each side of the wheel being granular and having such an average thickness that it weighs at least .004 gram per square centimeter at any given distance from the center of the wheel greater than .7r where r is the radius of the wheel, and said coating of metal on each side of the wheel being nowhere greater than .010 inch thick.

2. A cutting-off grinding wheel as claimed in claim 1 in which the metal coating on each side of the wheel is tin.

3. A cutting-off grinding wheel as claimed in claim 1 in which the metal coating on each side of the wheel is an alloy of tin with other metal selected from the group of claim 1.

4. Method of cutting metals which consists in feeding a rotating grinding wheel that comprises abrasive grains bonded together with phenolic resin bond and which has flat parallel sides against the metal in a direction perpendicular to its axis while lubricating the cut by means of metal selected from the group consisting of antimony, bismuth, cadmium, gallium, indium, lead, thallium and tin and alloys thereof.

5. Method according to claim 4 in which the lubricating metal is tin.

6. Method according to claim 4 in which the lubricating metal is an alloy of tin with other metals selected from the group of claim 4.

References Cited in the file of this patent UNITED STATES PATENTS 341,867 Andrews May 18, 1886 642,828 Spohn Feb. 6, 1900 2,038,727 Geyer Apr. 28, 1936 2,413,729 Rushmer Jan. 7, 1947 2,520,763 Goeppert etal. Aug. 29, 1950 FOREIGN PATENTS 417,085 Great Britain Sept. 27, 1934 441,406 Great Britain Jan. 20, 1936 622,673 Great Britain May 5, 1949 

